FORM - 2
THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENTS RULES, 2003
COMPLETE
Specification
(See Section 10; rule 13)
SOLAR POWER GENERATION SYSTEM
THERMAX LIMITED
an Indian Company
of D-13, MIDC Industrial Area,
R.D. Aga Road,
Chinchwad, Pune-411 019,
Maharashtra, India.
Inventors
l.JOSHI, YASHAVANT
2. PATKI, ANIL
3. SHAIKH, ABID
4. DUBAL, VILAS
The following specification particularly describes the invention and the manner
in which it is to be performed.

FIELD OF THE DISCLOSURE
The present disclosure generally relates to systems and methods used for generating power from renewable energy sources.
Particularly, the present disclosure relates to a solar power generation system.
BACKGROUND
Renewable energy is energy that can be obtained from natural renewable (naturally replenished) resources, such as sunlight, wind, rain, tides, geothermal heat and the like. Solar energy is a renewable form of green energy source with several advantages, such as, solar energy is safe, reliable and free of noises, consumes no fuel, involves less mechanical parts and thus has a less failure rate and requires comparatively less maintenance. Solar power is the power obtained by conversion of sunlight/ solar radiations into electricity or any other form of energy. Sunlight is directly converted into electricity by means of photovoltaic method. Alternatively, the sunlight is indirectly converted into electricity by means of heat from solar concentrators.
Some prior art patent documents are as follows:
For example, WIPO publication WO2012096715 discloses a solar energy collection system including support devices configured to accommodate misalignment of components during assembly. For example, the system includes piles fixed to the earth and an adjustable bearing assembly at the upper end of the pile. The adjustable bearing assembly can include at least one of a vertical adjustment device, a lateral adjustment device and an angular adjustment device. The adjustable bearing assembly may be a split type bearing,

made from two halves. The solar energy collection system can also include a plurality of solar energy collection device pre-wired together and mounted to a support member so as to form modular units. The system can also include enhanced supports for wire trays extending between rows of solar energy collection devices. However, the solar energy collection system disclosed by the WIPO publication WO2012096715 is comparatively ineffective and expensive.
Further, WIPO publication WO2012025184 discloses a drive module of a Fresnel mirror collector. The drive module includes a preferably electric motor, which is coupled to a mirror drive shaft by means of a reduction gear train, characterized by an angle sensor, which is integrated in the drive module. Also, the Fresnel reflector system includes a central solar tower. Further, the Fresnel reflector system includes a secondary reflector disposed above an absorber tube. However, the drive module/ Fresnel reflector system disclosed by the WIPO publication WO2012025184 is comparatively ineffective,
Furthermore, US publication US20090056699 discloses solar energy collector systems, components for solar energy collector systems, and methods for installing solar energy collector systems. The components for solar energy collector systems include solar radiation absorbers, receivers, drives, drive systems, reflectors, and various support structures. The solar energy collection systems, solar radiation absorbers, receivers, drives, drive systems, reflectors, support structures, and/or methods may be used, for example, in LFR solar arrays. However, the solar energy collection systems disclosed by US publication US20090056699 is comparatively ineffective and expensive.
Moreover, US publication US20080308091 discloses a solar tracking system with a torque tube supporting solar panels. Columns support the system and

have bearings for rotation of the torque tube. A drive is coupled to the torque tube and is driven by a gearbox, such as a worm gear assembly, for rotating the array of solar panels to follow the sun's diurnal motion. Drive mechanism 14, in one example a drive motor, provides the power to 3 drive shaft and associated linkage to move PV modules. The drive mechanism rotates the drive shaft, which in turn drives worm-gear assembly or drive pox. The array can rotate in an opposite direction, or backtrack, to prevent shadowing from one module row to another. Multiple gearboxes can be mechanically linked by drive shafts and driven by a single motor. The drive shafts may incorporate universal joints for uneven terrain or staggered configurations. Harmonic dampers can be affixed to the solar panels to decouple wind forces which allow the use of larger solar panels. However, the solar tracking system disclosed by US publication US20080308091 is comparatively ineffective.
Also, German patent document DEI9932646 discloses adjustable concentrator for solar installations with reflection strips coasting with gear and rack mechanism. The concentrator has several, simultaneously adjustable reflection strips, reflecting the solar radiation onto at least one absorber. Each reflection strip is coupled to at least one gearwheel and engaging a toothed rack without free play. The toothed rack is pressed against the gearwheels by bearings fitted at the side opposite to the toothed rack. The toothed rack is resiliency sprung, as are the bearings. The strips conform to a concentrator shape, as a parabola-shaped groove. However, the adjustable concentrator for solar installations as disclosed by German patent document DEI9932646 is comparatively ineffective.
Additionally, "A" shaped support structures are known in the prior art.

Although, there are numerous solar power generation systems are available in the prior art. The prior art solar power generation systems have numerous limitations. For example, the prior, art solar power generation systems are comparatively expensive. Further, the prior art solar power generation systems have application specific construction. Furthermore, the prior art solar power generation systems are comparatively difficult to erect.
Accordingly, there is need of a solar power generation system that is comparatively inexpensive. Further, there is need of a solar power generation system that is comparatively easy to erect. Furthermore, there is need of a solar power generation system that is comparatively more efficient. Moreover, there is need of a solar power generation system that is reliable in operation.
OBJECTS
Some of the objects of the system of the present disclosure which at least one embodiment herein satisfies are as follows:
It is an object of the system of the present disclosure to ameliorate one or more problems of the prior art or to at least provide a useful alternative.
An object of the system of the present disclosure is to provide a solar power generation system that is comparatively inexpensive.
Another object of the system of the present disclosure is to provide a solar power generation system that is comparatively easy to erect.
Yet another object of the system of the present disclosure is to provide a solar power generation system that is reliable in operation.

Further, an object of the system of the present disclosure is to provide a solar power generation system that is comparatively more efficient.
Moreover, an object of the system of the present disclosure is to provide a solar power generation system that is reliable in operation.
Other objects and advantages of the system of the present disclosure will be more apparent from the following description when read in conjunction with the accompanying figures, which are not intended to limit the scope of the present disclosure.
SUMMARY
In accordance with one aspect of the present disclosure, a solar power generation system is disclosed. The solar power generation system includes at least one primary reflector assembly, at least one receiver assembly, at least a pair of support structures and a tracking mechanism. The at least one primary reflector assembly facilitates concentration of solar radiations at a focal point.
The at least one primary reflector assembly includes a parabolic plate, a plurality of tubes and at least one reflector. The parabolic plate has a plurality of grooves configured thereon. The plurality of tubes is disposed in the plurality of grooves in a manner that at least some portion of at least some of the plurality of tubes protrudes above the parabolic plate. The at least one reflector is secured on at least some of the plurality of tubes for achieving parabolic curvature. The at least one receiver assembly is positioned substantially at the focal point of the primary reflector assembly. The receiver assembly includes a receiver tube and a secondary reflector assembly. The secondary reflector assembly is disposed operatively above the receiver tube and adapted to re-reflect solar radiations reflected from the

primary reflector assembly towards the receiver tube. The at least a pair of support structures provides support to the receiver assembly thereon. The tracking mechanism is adapted to track movement of the sun for facilitating significant impingement of solar radiations on the least one primary reflector assembly.
Typically, the plurality of tubes has a cross-section selected from a group consisting of a square, a circular, a triangular, an oval, an elliptical and a polygonal cross-section.
Typically, the at least one reflector is bonded to at least some of the plurality of tubes.
Further, the at least one reflector may be bonded to the plurality of tubes by means of adhesive.
In one embodiment, the solar power generation system includes a plurality of primary reflector assemblies adapted to move in tandem.
In another embodiment, the secondary reflector assembly has a "Π" shaped cross-section.
Typically, the secondary reflector assembly includes a backup frame and a plurality of secondary reflector elements of aluminum, glass or other materials. The plurality of secondary reflector elements is mounted on the backup frame.
Further, in one embodiment, the plurality of secondary reflector elements of aluminum, glass or other materials is mounted on the backup frame by means of mechanical fasteners.

Typically, each of the pair of support structures is shaped like an "A".
In one embodiment, a pair of plates is adapted to be connected to each of the support structures and disposed below an operative top plate of the support structures, wherein the receiver assembly is connected to the pair of plates for facilitating support to the at least one receiver assembly on the pair of support structures.
In one embodiment, the tracking mechanism includes a motor, a gear box, an externally threaded screw, an internally threaded screw and a rack and pinion mechanism. The gear box is operated by the motor. The externally threaded screw is operated by the gear box. The internally threaded screw is in threaded engagement with the externally threaded screw for converting rotational motion to linear motion. The rack and pinion mechanism is operated by the internally threaded screw and connected to the primary reflector assembly, wherein the rack and pinion mechanism is adapted to configure rotational movement of the primary reflector assembly for tracking movements of the Sun.
In one embodiment, the solar power generation system includes at least a pair of split bearing housings, wherein each of the pair of split bearing housings includes self- lubricating bearings, and wherein each of the pair of split bearing housings includes a lower housing portion and an upper housing portion, the lower housing portion is mounted on a base frame and the upper housing portion is connected to the lower housing portion by means of at least one mechanical fastener.
Typically, the base frame has a modular structure.

BRIEF DESCRIPTION OF ACCOMPANYING DRAWINGS
The solar power generation system of the present disclosure will now be explained in relation to the non-limiting accompanying drawings, in which:
Figure 1 illustrates a front view of a primary reflector assembly of a solar power generation system of the present disclosure, in accordance with one embodiment;
Figure 2 illustrates a perspective view of the primary reflector assembly of Figure 1;
Figure 3 illustrates a perspective view of a receiver assembly of the solar power generation system of the present disclosure, in one embodiment;
Figure 4 illustrates a perspective view of a support structure along with a base frame, in one embodiment;
Figure 5 illustrates a perspective view depicting the base frame of Figure 4;
Figure 6 illustrates a perspective view depicting before assembly position of the secondary reflector assembly with the support structure;
Figure 7 illustrates a perspective view depicting after assembly position of the secondary reflector assembly with the support structure;

Figure 8 illustrates a schematic representation of a tracking mechanism of the solar power generation system of the present disclosure, in accordance with one embodiment; and
Figure 9 illustrates a perspective view of a split self-lubricating bearing along with its split housing in a dis-assembled position, in accordance with one embodiment.
DETAILED DESCRIPTION OF THE ACCOMPANYING DRAWINGS
The solar power generation system of the present disclosure will now be described with reference to the accompanying drawings which do not limit the scope and ambit of the disclosure. The description provided is purely by way of example and illustration.
The embodiments herein and the various features and advantageous details
thereof are explained with reference to the non-limiting embodiments in the
following description. Descriptions of well-known components and processing
techniques are omitted so as to not unnecessarily obscure the embodiments
herein. The examples used herein are intended merely to facilitate an
understanding of ways in which the embodiments herein may be practiced and
to further enable those of skill in the art to practice the embodiments herein. t
Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
The description hereinafter, of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific

embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.
In general, the structural and functional configuration of a plurality of arcuate connecting elements of "Π" shaped cross-section for a solar trough is discussed in a co-pending Indian Patent Application No. 2996/MUM/2011 in the name of Thermax Limited, the contents of which are incorporated herein by reference in its entirety.
Referring to Figures 1 to 9, a solar power generation system is illustrated. The solar power generation system includes at least one primary reflector assembly 200 (illustrated in Figures 1 to 2), at least one receiver assembly 300 (illustrated in Figure 3, 6 and 7), at least a pair of support structures 400 (illustrated in Figures 4, 6 and 7 ) and a tracking mechanism 500 (illustrated in Figure 8).
Referring to Figures 1 to 2, the at least one primary reflector assembly 200 facilitates concentration of solar radiations at a focal point. The at least one primary reflector assembly 200 includes a parabolic plate 202, a plurality of tubes 204 and at least one reflector 206. The parabolic plate 202 has a plurality of grooves 208 configured thereon. The plurality of tubes 204 is disposed in the

plurality of grooves 208 in a manner that at least some portion of at least some of the plurality of tubes 204 protrudes above the parabolic plate 202.
In one embodiment, the plurality of tubes 204 is secured in the plurality of grooves 208 by means bat not limited welding, adhesive and the like. The plurality of tubes 204 is closely spaced and disposed along the length of the parabolic plate 202 so as to achieve desired optical concentration from all the points on the surface of the reflector 206. In one embodiment, the plurality of tubes 204 is positioned tangential to the desired profile curve and are small in size to reduce the local flattening effect. In one embodiment, the plurality of tubes 204 has a cross-section selected from a group consisting of a square, a circular, a triangular, an oval, an elliptical and a polygonal cross-section. In another embodiment, the plurality of tubes 204 has a quadrangular cross-section. More specifically, in yet another embodiment, the quadrangular cross-section is a square cross-section. Still in yet another embodiment, the plurality of tubes 204 has a rectangular cross-section. Further, in yet another embodiment, the plurality of tubes 204 has a T-shaped cross-section. Furthermore, in yet another embodiment, the plurality of tubes 204 has an inverted triangle shaped cross-section. However, the present invention is not limited to any particular cross-section of the plurality of tubes 204.
The at least one reflector 206 is secured on the plurality of tubes 204 for achieving parabolic curvature and uniform bending. In one embodiment, the at least one reflector 206 has a thickness in the range of 0.5mm to 6mm. In one embodiment, the at least one reflector 206 is bonded to the plurality of tubes 204. More specifically, in yet another embodiment the at least one reflector 206 is bonded to the plurality of tubes 204 by means of adhesive. In one

embodiment, the square shaped plurality of tubes 204 facilitates reduced adhesive consumption.
Further, in one embodiment, the solar power generation system 100 includes a plurality of primary reflector assemblies, such as the primary reflector assembly 200. Each of the plurality of primary reflector assemblies is connected to the tracking mechanism 500 and adapted to move in tandem based on the movement of the tracking mechanism 500.
Referring to Figures 3, 6 and 7, the at least one receiver assembly 300 is positioned substantially at the focal point of the primary reflector assembly 200. The at least one receiver assembly 300 includes a receiver tube/ absorber tube 302 and a secondary reflector assembly 304. The secondary reflector assembly 304 is disposed operatively above the receiver tube 302 and adapted to re-reflect solar radiations reflected from the primary reflector assembly 200 towards the receiver tube 302.
In one embodiment, the secondary reflector assembly 304 has a "π" shaped cross-section. However, the present disclosure is not limited to any particular cross-section of the secondary reflector assembly 304. The secondary reflector assembly 304 includes a backup frame 306 and a plurality of secondary reflector elements 308 (illustrated in Figures 6 and 7). In one embodiment, the plurality of secondary reflector elements 308 is of aluminum, glass or other materials. However, the present disclosure is not limited to any particular material used for manufacturing the plurality of secondary reflector elements 308. The plurality of secondary reflector elements 308is mounted on the backup frame 306. Also, the receiver tube 302 is connected to the back-up frame 306. The backup frame 306 of the receiver assembly 300 is adapted to secure both

the secondary reflector assembly 304 and the receiver tube 302. Also, the backup frame 306 includes a pair of end plates 310 on either side that may be mounted to the support structures 400 while erection.
In other embodiments, the plurality of reflectors 308 may be manufactured from various materials such as metals such as chromium and non-metals such as carbon fiber, Polyethylene and the like. In one embodiment, the plurality of aluminum reflectors 308 is mounted on the backup frame 306 by means of mechanical fasteners.
Referring to Figures 4, 6 and 7, the pair of support structures 400 provides support to the receiver assembly 300 thereon and ease of assembly of the receiver assembly 300. In one embodiment, each of the pair of support structures 400 is shaped like an "A". However, the present disclosure is not limited to any particular shape of the each of the pair of support structures 400.
In one embodiment, a pair of plates 402 (illustrated in Figure 6) is adapted to be connected to each of the pair of support structure 400 and disposed below an operative top plate 404 (illustrated in Figures 6 and 7) of the support structures 400. To these plates 402 the receiver assembly 300 is bolted after lifting it up from the ground with help of pulley and rope. The receiver assembly 300 is connected to the plates 402 for facilitating support to the at least one receiver assembly 300 on the pair of support structures 400. The pair of support structures 400 is adapted to take care of wind loads and to keep deflections at the receiver assembly 300 within acceptable range.
Referring to Figures 4 to 5, the pair of support structures 400 is supported on a base frame 450. In one embodiment, the base frame 450 has a modular

structure. The modular structure of the base frame 450 facilitates easy storage, transportation and assembly of the base frame 450.
Referring to Figure 8, the tracking mechanism 500 is adapted to track movement of the sun for facilitating significant impingement of solar radiations on the at least one primary reflector assembly 200. In one embodiment, the tracking mechanism 500 includes a motor 502, a gear box 504, an externally threaded screw 506, an internally threaded screw 508 and a rack and pinion mechanism 510. The gear box 504 is operated by the motor 502. The externally threaded screw 506 is operated by the gear box 504. The internally threaded screw 508 is in threaded engagement with the externally threaded screw 506 for converting rotational motion to linear motion. The rack and pinion mechanism 510 is operated by the internally threaded screw 508 and connected to the primary reflector assembly 200.
The rack and pinion mechanism 510 is adapted to configure rotational movement of the primary reflector assembly 200 for tracking movements of the Sun. The pinion 512 extends on either side to get mounted to the primary reflector assembly 200 with flanges. The pinion 512 with flanges is constructed in compact manner so as to reduce losses. A connecting rod is used to connect each reflector's rack 514 with next one. This has oppositely threaded nuts on either side which helps to fine tune the reflector's slope angles. The tracking mechanism 500 is adapted to convert rotary motion into translational motion. In one embodiment, the tracking mechanism 500 includes a PLC controller for accurately tracking of the movements of the sun.
Referring to Figure 9, in one embodiment, the solar power generation system further includes at least a pair of split bearing housings 600. The pair of split

bearing housings 600 is attached on either end of the primary retlector assembly 200 for its smooth operation and it also helps in easy assembly of the primary reflector assembly 200. In one embodiment, each of the pair of split bearing housing 600 includes a lower housing portion 602 and an upper housing portion 604. The lower housing portion 602 is mounted on the base frame 450 (illustrated in Figures 4 to 5) and the upper housing portion 604 is connected to the lower housing portion 602 by means of at least one mechanical fastener 608.
Further, the each of the pair of split bearing housings includes self- lubricating bearings 610. The self- lubricating bearings 610 are also split-bearings. The self- lubricating bearings 610 facilitates rotational movement of the primary reflector assembly 200. In one embodiment, each of the self- lubricating bearings 610 provides dry lubrication. Further, in one embodiment, each of the self- lubricating bearings 610 may be of self-lubricating materials such as Teflon, Graphite, Polytetrafluoroethylene (PTFE) and the like. In another embodiment, the self- lubricating bearings 610 may be coated with the self-lubricating materials such as Teflon, Graphite and the like. However, the present invention is not limited to self-lubricating structures as described above.
As the reflectors 206 of the primary reflector assembly 200 has comparatively improved parabolic curvature and formed by uniform bending, the primary reflector assembly 200 facilitates comparatively improved reflections of impinged solar radiations towards the receiver assembly 300. Further, the secondary reflector assembly 304 of the receiver assembly 300 re-reflects the solar radiations reflected from the primary reflector assembly 200 towards the receiver tube 302 for minimization of losses. Also, the tracking mechanism 500 adapted to track movement of the sun for facilitating significant impingement of solar radiations on the primary reflector assembly 200. Accordingly, the solar

power generation system 100 of the present disclosure is comparatively more efficient.
TECHNICAL ADVANCEMENTS AND ECONOMICAL
SIGNIFICANCE
The technical advancements offered by the system of the present disclosure which add to the economic significance of the disclosure include the realization of:
• a solar power generation system that is comparatively inexpensive;
• a solar power generation system that is comparatively easy to erect;
• a solar power generation system that is comparatively more efficient;
• a solar power generation system that is reliable in operation;
• a solar power generation system that has a modular structure; and
• a solar power generation system that has a roof mounted construction.
Throughout this specification the word "comprise", or variations such as "comprises" or "comprising1', will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps.

The use of the expression "at least" or "at least one" suggests the use of one or more elements or ingredients or quantities, as the use may be in the embodiment to achieve one or more of the desired objects or results.
Any discussion of documents, acts, materials, devices, articles or the like that has been included in this specification is solely for the purpose of providing a context for the disclosure. It is not to be taken as an admission that any or all of these matters form part of the prior art base or were common general knowledge in the field relevant to the disclosure as it existed anywhere before the priority date of this application.
The numerical values mentioned for the various physical parameters, dimensions or quantities are only approximations and it is envisaged that the values higher/lower than the numerical values assigned to the parameters, dimensions or quantities fall within the scope of the disclosure, unless there is a statement in the specification specific to the contrary.

We claim:
1. A solar power generation system comprising:
• at least one primary reflector assembly for facilitating
concentration of solar radiations at a focal point, said at least one
primary reflector assembly comprising,
o a parabolic plate having a plurality of grooves configured
thereon; o a plurality of tubes disposed in said plurality of grooves in
a manner that at least some portion of at least some of the
plurality of tubes protrudes above said parabolic plate; o at least one reflector secured on at least some of said
plurality of tubes for achieving parabolic curvature,
• at least one receiver assembly positioned substantially at said
focal point of said primary reflector assembly, said receiver
assembly comprising,
o a receiver tube;
o a secondary reflector assembly disposed operatively above said receiver tube and adapted to re-reflect solar radiations reflected from said primary reflector assembly towards said receiver tube; and
• at least a pair of support structures for providing support to said receiver assembly thereon; and
• a tracking mechanism adapted to track movement of the sun for facilitating significant impingement of solar radiations on said least one primary reflector assembly.
2. The solar power generation system as claimed in claim 1, wherein said
plurality of tubes has a cross-section selected from a group consisting of a
square, a circular, a triangular, an oval, an elliptical and a polygonal cross-
section.

3. The solar power generation system as claimed in claim 1, wherein said at least one reflector is bonded to at least some of said plurality of tubes.
4. The solar power generation system as claimed in claim 1, wherein said at least one reflector is bonded to said plurality of tubes by means of adhesive.
5. The solar power generation system as claimed in claim 1; further comprising a plurality of primary reflector assemblies, wherein said plurality of primary reflector assemblies are adapted to move in tandem.
6. The solar power generation system as claimed in claim 1, wherein said secondary reflector assembly has a "7r" shaped cross-section.
7. The solar power generation system as claimed in claim 1, wherein said secondary reflector assembly comprises,
i. a backup frame; and
ii. a plurality of secondary reflector elements of aluminum, glass or other materials mounted on said backup frame.
8. The solar power generation system as claimed in claim 1, wherein said plurality of secondary reflector elements of aluminum, glass or other materials is mounted on said backup frame by means of mechanical fasteners.
9. The solar power generation system as claimed in claim 1, wherein each of said pair of support structures is shaped like an "A".

lO.The solar power generation system as claimed in claim 1, further comprising a pair of plates adapted to be connected to each of said support structures and disposed below an operative top plate of said support structures, wherein said receiver assembly is connected to said pair of plates for facilitating support to said at least one receiver assembly on said pair of support structures.
11 .The solar power generation system as claimed in claim 1, wherein said tracking mechanism comprises,
o a motor;
o a gear box operated by said motor;
o an externally threaded screw operated by said gear box;
o an internally threaded screw in threaded engagement with said externally threaded screw for converting rotational motion to linear motion; and
o a rack and pinion mechanism operated by said internally threaded screw and connected to said primary reflector assembly, wherein said rack and pinion mechanism is adapted to configure rotational movement of said primary reflector assembly for tracking movements of the Sun.
12. The solar power generation system as claimed in claim 1, further comprising at least a pair of split bearing housings, wherein each of said pair of split bearing housings comprises self- lubricating bearings, and wherein each of said pair of split bearing housings comprises a lower housing portion and an upper housing portion, said lower housing portion being mounted on a base frame and said upper housing portion being connected to the lower housing portion by means of at least one mechanical fastener.

13. The solar power generation system as claimed in claim 13, wherein said base frame has a modular structure.